IS 15541:2005 w?i+kTwmF wFT1-wmiEFit m-TwlaaTFm%k-mlrw w22JGmri{dPm-@T4Nz . Indian Standard LOW CEMENT AND ULTRA LOW CEMENT CASTABLES FOR GENERAL PURPOSES -- SPECIFICATION ICS 81.080 0 BIS 2005 BUREAU MANAK OF BHAVAN, INDIAN STANDARDS ZAFAR MARG 9 BAHADUR SHAH NEW DELHI 110002 February 2005 Price Group 2 Refractories Sectional Committee, MTD 15 FOREWORD This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by the Refractories Sectional Committee, had been approved by the Metallurgical Engineering Division Council. This standard has been prepared for specifying the requirements of low cement and ultra low cement castables for general purpose. Six grades of low cement castables and two types of ultra low cement castables and their methods of sampling have been specified in this standard. For the purpose of deciding whether a particular requirement of this standard is complied with the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS 2:1960 `Rules for rounding off numerical values (revised)'. The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard. IS 15541:2005 Indian Standard LOW CEMENT AND ULTRA LOW CEMENT CASTABLES FOR GENERAL PURPOSES -- SPECIFICATION 1 SCOPE This standard covers the requirements of low cement castables and ultra low cement castables for general purpose. The specific uses may be decided by mutual understanding between the manufacturer and purchaser. The scope also describes the method of sampling. 2 REFERENCES The following standards contain provisions, which through reference in this text, constitute provisions of this standard. At the time of publication, the editions were valid. All standards are subject to revision, and parties to agreement based on this standard are encouraged to investigate the possibility of applying the most recent editions of the standard indicated below: IS No. Title graded refractory agreegates with high aluminina cement in order to have total CaO content between 0.31 to 0.5 per cent, the plasticisers may also be incorporated in the ultra low cement castables. 3.4 Lot -- In any consignment, all the containers containing low cement and ultra low cement castables of the same type and grade, manufactured by the same firm under similar conditions of production shall be grouped together to constitute a lot. The maximum mass of any lot however shall be limited to 25 tonnes. 4 SAMPLING AND TEST PIECE PREPARATIONS 4.1 For the complete series of test a minimum quality of about 50 kg is required as sample. As those are normally supplied in 50 kg containers, the number of containers mentioned below shall be released at random on the following basis: Lot Size No. of 50 kg Containers/ Bags to be Selected as Sample') (2) 1527:1972 Methods of chemical analysis of high silica refractory materials ~irst revision) 1528 (Part 1): 1980 Method of sampling and physical tests for refractory materials: Determination of pyrometric cone equivalent (PCE) or softening point (second revision) Sieve analysis @rst revision) (1) Up to and including 1 tonne Over 1 tonnes and up to and including 4 tonnes Over 4 tonnes and up to and including 25 tonnes least 10 locations randomly. 1 2 5 (Part 14) :1974 (Part 16) :1991 4041:1987 10570:1983 Determination ofthermal conductivity up to 1250°C of dense and insulating refractory products according to the hot wire parallel method Glossary of terms relatingto refractory materials Method foresting refractory castables o Eachcontainerhag sample shall be made available from at 4.2 The selected containerdbags shall be emptied on a suitable dry surface and the material be thoroughly mixed and reduced to 50 kg by coning and quartering. This final sample shall be divided equally into eight test samples by successive coning and quartering method. These test samples shall be used for various physical tests, sieve analysis, bulk density, permanent linear change, pyrometric cone equivalent, modulus of rupture, cold crushing strength and thermal conductivity. 4.3 Preparation of Test Pieces 3 TERMINOLOGY 3.1 For the purpose of this standard, the following definitions in addition to those giveninIS4041 shall apply. 3.2 Low Cement Castabies -- Mixture of graded refractory agreegates with high alumina cement in order to have total CaO content between 1-2 per cent. The plasticisers may also be incorporated in the low cement castables. 3.3 Ultra Low Cement Castables -- Mixture of The method of preparing test pieces of the material has a marked effect on their properties and it is necessary to use a standard procedure. IS 15541:2005 4.3.1 Apparatus The apparatus used for the specimen preparation for bulk density, firing, shrinkage, modulus of rupture and cold crushing strength are: a) b) c) d) h40ula!s-- as per 7.1.1 of IS 10570. Planetary bowl mixer -- as per 7.1.3 of Is 10570. Vibrating table -- as per 7.1.4 of IS 10570. Drying oven.. 6.2 The requirement of physical tests for ultra low cement castables is given in Table 2. 6.3 Maximum Grain Size Wet sieve anlaysis for castables, shall be carried out in accordance with IS 1528 (Part 14). Grading shall be as per agreement between the manufacturer and the purchaser. 6.4 Flow properties shall be tested as given in Annex A of Is 10570. 6.5 Bulk density shall be determined as per method specified in 8 of IS 10570. 6.6 Cold crushing strength shall be determined as per specified in 10 of IS 10570. 6.7 Permanent linear change shall be determined as per method specified in 11 of IS 10570. 6.8 Thermal conductivity test shall be carried out in accordance with IS 1528 (Part 16) of any other suitable method can be used as agreed between the manufacturer and the purchaser. 7 DETERMINATION EQUIVALENT (PCE) OF PYROMETRIC CONE 4.3.2 Test Pieces The test pieces used for the tests prescribed in 4.2 shall be in the form of bar 40 mm x 40 mm x 160 mm. These test pieces shall be cast using gang mould of three bars as per IS 10570. The consistency of the material, for the test pieces, shall be as per instructions given by manufacturer. When shaping is completed the moulds with compacted test specimens are kept for 24 h in mould. After 24 h, the test pieces are removed from the mould and placed for drying at 11O°C in an oven to constant weight. After drying, the test pieces are cooled to room temperature and dimensions are measured. In special cases, the curing schedule as recommended by the manufacturers maybe adopted. 5 CHEMICAL ANALYSIS 7.1 The test shall be carried out in accordance with 1S 1528 (Part 1). 8 PACKING 8.1 These castables shall be packed in polythene lined 5.1 Chemical analysis, for low cement castable when carried out in accordance with IS 1527 shall be as given in Table 1. 5.2 Chemical anlaysis for ultra low cement castable when carried out in accordance with IS 1527 shall be as given in Table 2. 6 PHYSICAL PROPERTIES HDPE bags/containers of suitable weights. 9 MARKING 9.1 All the bags shall be marked with: a) b) 6.1 The requirement of physical tests for low cement castable is given in Table 1. Manufacturers weight and name, product name, net Month and year of manufacture. 2 IS 15541:2005 Table 1 Requirement for Low Cement Castable (Clauses 5.1 and 6.1) Grade (1) Chemical Analysis (weight percent) Min AIzOJ, SiOz, Max FezOj, Max TIo*, Max 45 (2) 45 60 (3) . 60 70 (4) 70 25 1.5 2.8 80 (5) 80 13 1.8 3.3 90 (6) 90 06 1.0 1.2 1.7 60 6 4.2-5.0 3.0 950 1100 -- 1200 37/1 820 95 (7) 94 4.2 0.3 48 1.5 2.4 35 1.5 2.6 Traces 1.2 CaO,Max Physical Properties MOR at 1400"C kgf/cm2 Maximum GrainSize,mm Waterfor Casting, percent B.D. (gin/cc) at 110°C/24 h, A4in C.C.S. kg/cm2, Min 110°C/24h 1 100"C/3 h 1 500°C/3 h 15 50°C/3 h Refractories Ortorr/°C, &fin 2.0 50 6 4.8-5.5 2.3 700 900 1000 3211717 2.0 50 6 4.7-5.4 2.6 750 900 1000 -- 36/1 804 2.0 50 6 4.0-4.6 2.65 750 950 1000 36/1 804 2.0 50 6 3.8-4.5 2.9 800 1050 -- 1150 37/1 820 60 6 4.0-4.8 3.1 1000 1100 1250 38/1 835 PLC(percent) I 100°C/3 h, Max h, Max I 500"C/3 I 550°C/3 h, Max Thermal Conductivity (kcal/m/hP'C) 400"C 600"C 800"C Storage Life (months) +(3.30 +1.0 -- 0.85 1.05 1.20 6 +0,30 +1.0 -- 0.95 1.10 1.25 6 +0.30 +1.0 1.15 1.25 1.30 6 +0.20 -- +1.5 1.70 1.75 1.80 6 *0.30 -- +0.80 2.20 2.30 2.35 6 +0.30 -- &O.80 2.25 2.30 2.35 6 Table 2 Requirement for Ultra Low Cement Castables (Clauses 5.2 and 6.2) Type (1) MOR at 1 400"C Chemical Analysis (weight percent) AllOj, Min FelOJ, Max CaO, Max Water, percent CCS kg/cm2, MirI I I0°C/24 h I 100°C/3 h I 550°C/3 h MOR 11O°C/24h I 1OO°C/3h I 550°C/3 h PLC, percent 1 i 00°C/3 h 1 550°C/ 3 h Storage life (months) 90 Percent (2) 60 90 1.5 95 Percent (3) 60 95 0.5 0.5 4-4.5 200 800 I 200 50 150 220 +0.3 *I 6 0.5 4-4.5 400 900 1100 50 I50 200 *0.3 +] 6 3 Bureau of Indian Standards BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote harmonious development of the activities of standardization, marking and quality certification of goods and attending to connected matters in the country. Copyright BIS has the copyright of all its publications. No part of these publications may be reproduced in any form without the prior permission in writing of BIS. This does not preclude the free use, in the course of implementing the standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating to copyright be addressed to the Director (Publications), BIS. Review of Indian Standards Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed periodically; a standard along with amendments is reaffkmed when such review indicates that no changes are needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of `BIS Catalogue' and' Standards: Monthly Additions'. This Indian Standard has been developed from Doc : No. MTD 15 (4346). Amendments Issued Since Publication Amend No. Date of Issue Text Affected BUREAU OF INDIAN STANDARDS Headquarters : Manak Bhavan, 9 Brthadur Shah Zafar Marg, New Delhi 110002 Telephones :23230131,23233375,, 23239402 Regional Offices : Central Eastern Northern Southern Western : Manak Bhavan, 9 Bahadur Shah Zafar Marg NEW DELHI 110002 : 1/14 C.I.T. Scheme VII M, V. I. P. Road, Kankurgachi KOLKATA 700054 : SCO 335-336, Sector 34-A, CHANDIGARH 160022 : C.I.T. Campus, IV Cross Road, CHENNAI 600113 : Manakalaya, E9 MIDC, Marol, Andheri (East) MUMBAI 400093 Telegrams : Mrtnaksanstha (Common to all offices) Telephone 23237617 { 23233841 23378499,23378561 { 23378626,23379120 2603843 { 2609285 22541216,22541442 { 22542519,22542315 ~283292 ~283278 95,28327858 91,28327892 Branches : AHMEDABAD. BANGALORE. BHOPAL. BHUBANESHWAR. COIMBATORE. FARIDABAD. GHAZIABAD. GUWAHATI. HYDERABAD. JAIPUR. KANPUR. LUCKNOW. NAGPUR. NALAGARH. PATNA. PUNE. RAJKOT. THIRUVANANTHAPURAM. VISAKHAPATNAM. Printed at Frabhat Offset Press, New Delhi-2